Inspection

COUNTER SHAFT AND GEAR


Inspection


COUNTER SHAFT AND GEAR
If the contact surface on each gear and counter shaft. has damage, peeling, abrasion, dent, bent, or any other damage, replace the components.






SYNCHRONIZER

Synchronizer Hub and Coupling Sleeve
- If the contact surface on coupling sleeve, synchronizer hub, and shifting insert has damage or abrasion, replace the components.
- Coupling sleeve and synchronizer hub shall move smoothly.






Bulk Ring and Spread Spring
- If the cam surface on baulk ring or contact surface on insert has damage or excessive wear, replace with a new one.
- If spread spring is damaged, replace with a new one.






Bulk Ring Clearance for Double Cone Synchronizer (4th)
Check the clearance between outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) as follows.

CAUTION:
The clearances "A" and "B" are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set. Replace them as a set if the clearances are outside the limit value.





1. Measure the clearance "A" at 2 points or more diagonally opposite using a dial indicator (B) and the puller (C) [SST:
ST30031000 (J-22912-01)]. And then calculate mean value.





Clearance "A"
Standard value : Refer to Bulk Ring Clearance Baulk Ring Clearance
Limit value : Refer to Bulk Ring Clearance Baulk Ring Clearance





2. Measure the clearance "B" at 2 points or more diagonally opposite using a feeler gauge (A). And then calculate mean value.

Clearance "B"
Standard value : Refer to Baulk Ring Clearance

Limit value : Refer to Baulk Ring Clearance


Bulk Ring Clearance for Triple Cone Synchronizer (3rd)
Check the clearance between outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) as follows.





CAUTION:
The clearances "A", "B" and "C" are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set. Replace them as a set if the clearances are outside the limit value.
1. Measure the clearance "A" at 2 points or more diagonally opposite using a feeler gauge (B) when pressing outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) toward gear taper cone (C). And then calculate mean value.





Clearance "A"
Standard value : Refer to Baulk Ring Clearance

Limit value : Refer to Baulk Ring Clearance

2. Measure the clearance "B" at 2 points or more diagonally opposite using a feeler gauge (A). And then calculate mean value.





Clearance "B"
Standard value : Refer to Baulk Ring Clearance
Limit value : Refer to Baulk Ring Clearance





3. Measure the clearance "C" at 2 points or more diagonally opposite using a feeler gauge (A) when pressing outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) toward gear taper cone (B). And then calculate mean value.

Clearance "C"
Standard value : Refer to Baulk Ring Clearance
Limit value : Refer to Baulk Ring Clearance





BEARING
If the bearing does not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with new ones.